Minarik RG501A User manual

User’s Manual
RRGG550011AA//RRGG551111AA
Cased, Regenerative, Variable Speed DC Drives
250-0234 rev 1.qxd 3/12/99 11:14 AM Page I

Copyright  1998 by
Minarik Corporation
All rights reserved. No part of this manual may be reproduced or transmitted in any form without written
permission from Minarik Corporation. The information and technical data in this manual are subject to
change without notice. Minarik Corporation and its Divisions make no warranty of any kind with respect
to this material, including, but not limited to, the implied warranties of its merchantability and fitness for a
given purpose. Minarik Corporation and its Divisions assume no responsibility for any errors that may
appear in this manual and make no commitment to update or to keep current the information in this
manual.
Printed in the United States of America.
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mSafety Warnings
•This symbol m denotes an important safety tip or warning. Please
read these sections carefully prior to performing any of the instructions
contained in that section.
• Have a qualified electrical maintenance technician install, adjust and
service this equipment. Follow the National Electrical Code and all
other applicable electrical and safety codes, including the provisions of
the Occupational Safety and Health Act (OSHA), when installing
equipment.
•Reduce the chance of an electrical fire, shock, or explosion by proper
grounding, over-current protection, thermal protection, and enclosure.
Follow sound maintenance procedures.
•It is possible for a drive to run at full speed as a result of a
component failure. Please ensure that a master switch has been placed
in the AC line to stop the drive in an emergency.
•This drive is isolated from earth ground. Circuit potentials are at
115 VAC or 230 VAC above earth ground. Avoid direct contact with
the printed circuit board or with circuit elements to prevent the risk of
serious injury or fatality. Use a non-metallic screwdriver for adjusting
the calibration trimpots.
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ii
Contents
Introduction 1
Specifications 2
Dimensions 3
Regenerative Drives 4
Installation 5
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Field fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Cage-clamp terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Field output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Limit switch connections (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Remote pushbuttons (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Slide switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Mode select switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Operation 12
Before applying power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Jogging the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Limit switch operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Calibration 17
Power board trimpots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
MIN SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
MAX SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
FWD ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
REV ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
IR COMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
FWD TQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
REV TQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
DB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Logic board trimpots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
FWD JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
REV JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
DWELL TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
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iii
Troubleshooting 24
Block Diagram 28
Prewired Connections 29
Replacement Parts 30
Cerificate of Compliance 31
Limited Warranty inside back cover
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iv
Illustrations
Fig. Description Page
1. RG501A and RG511A Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2. Four-Quadrant Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3. Line and Field Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4. Cage-clamp terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
5. Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
6. Limit switch connections (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
7. Remote pushbuttons (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
8. Slide switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
9. Mode select switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
10. Typical FWD TQ, REV TQ and IR COMP Settings for RG501A . . . . . . . . . . . . . . .19
11. Typical FWD TQ, REV TQ and IR COMP Settings for RG511A . . . . . . . . . . . . . . .20
12. Deadband Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
13. Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
14. Prewired Connections (Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
17. Prewired Connections (Signal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
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v
Tables
Fig. Description Page
1. Recommended Line Fuse Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2. Field Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4. AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
5. Armature Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
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vi
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1
Specifications
Max.
Armature HP Range HP Range
Current with 115 VAC with 230 VAC
Model (Amps DC) Applied Applied
RG501A 10.0 1/4–1 1/2–2
RG511A 3.0 1/20–1/8 1/10–1/4
AC Line Voltage 115/230 VAC, ±10%, 50/60 Hz, single phase
Armature Voltage (115 VAC Input) 0–90 VDC
Armature Voltage (230 VAC Input) 0–180 VDC
Form Factor 1.37 at base speed
Field Voltage (115 VAC Input) 50 VDC (F1 to L1); 100 VDC (F1 to F2)
Field Voltage (230 VAC Input) 100 VDC (F1 to L1); 200 VDC (F1 to F2)
Maximum Field Current 1 ADC
Acceleration Time Range (with no load) 0.5–15 seconds
Deceleration Time Range (with no load) 0.5–15 seconds
Analog Input Voltage Range (isolated; RB1 to S2) –10 to +10 VDC
Input Impedance (RB1 to S2) 32K ohms
Load Regulation
with Armature Feedback 1% of base speed or better
with Tachogenerator Feedback 0.1% of base speed
Dwell Time 0.1 – 1 second (0.1 second increments)
Vibration 0.5G max. (0–50 Hz)
0.1G max. (>50 Hz)
Ambient Temperature Range 10°C–40°C
Weight 8.3 lb
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2
Dimensions
Figure 1. RG501A and RG511A Dimensions
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3
Regenerative Drives
Most non-regenerative, variable-speed DC drives control current flow
to a motor in one direction. The direction of current flow is the same
direction as the motor rotation. Non-regenerative drives operate in
Quadrant 1, and also in Quadrant 3 if the drive is reversible (see Figure 2).
Motors must stop before reversing direction. Unless dynamic braking is
used, non-regenerative drives cannot oppose an overhauling load, and
cannot decelerate a load faster than coasting to a lower speed.
Regenerative drives operate in two additional quadrants: Quadrant 2 and
Quadrant 4. In these quadrants, motor torque is in the opposite direction of
motor rotation.
Regenerative drives can reverse a motor without contactors, switches,
brake resistors, or inhibit plugs. They can also control an overhauling load
and decelerate a load faster than it would take to coast to a lower speed.
Figure 2. Four Quadrant Operation
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4
Installation
Mounting
NEMA 4X cased drives come with three 0.88 inch (22 mm) conduit
knockout holes at the bottom of the case. The units may be vertically wall
mounted using the four 0.25 inch (6 mm) slotted holes on the attached heat
sink. For motor loads less than 5 ADC, the drive may be bench mounted
horizontally, or operated without mounting.
1. Install the mounting screws.
2. For access to the terminal strip, turn the slotted screw on the front cover
counterclockwise until it is free from the case. The right side of the
cover is hinged to the case. Lift or pull the slotted screw to open the
case.
3. Carefully remove the conduit knockouts by tapping them into the case
and twisting them off with pliers.
4. Install conduit hardware through the 0.88 inch (22 mm) conduit holes.
Connect external wiring to the terminal block.
5. Grasp the slotted screw and tilt the front cover back into place. Avoid
pinching any wires between the front cover and the case.
6. Turn the slotted screw clockwise until tight to secure the front cover.
7. Set the POWER switch to the 0(OFF) position before applying the AC
line voltage.
Wiring
Use 14 AWG wire for AC line voltage (L1 and L2) and motor armature
(A1 and A2) wiring. Use 16 AWG wire for motor field (F1 and F2) and
tachogenerator (T1 and T2) wiring.
(continued)
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5
Installation
Use shielded cable if wires are longer than 12 inches (30 cm) to avoid
picking up unwanted electrical noise.
It may be necessary to earth ground the shielded cable. If noise is
produced by devices other than the drive, ground the shield at the drive
end. If noise is generated by a device on the drive, ground the shield at the
end away from the drive. Do not ground both ends of the shield.
Do not bundle logic wires with power carrying wires that can cause
erratic operation. Keep logic wires in a conduit separated by at least 2
inches from power carrying wires. Do not allow logic wires to travel in
parallel to power carrying wires for more than 1 inch.
Line fusing
RG501A and RG511A drives have line fuses preinstalled to fuseholders
FU501 and FU502 (see Figure 3 for location). Factory installed line fuses
are rated for maximum rated horsepower. Resize line fuses if a lower rated
horsepower motor is used. Table 1 lists the recommended line fuse sizes.
Use fast acting fuses rated for 250 VAC or higher, and approximately
150% of the maximum armature current.
Table 1. Recommended Line Fuse Sizes
90 VDC Motor 180 VDC Motor Max. DC Armature AC Line Fuse
Horsepower Horsepower Current (amps) Size (amps)
1/20 1/10 0.5 3
1/15 1/8 0.8 3
1/8 1/4 1.5 5
1/6 1/3 1.7 5
1/4 1/2 2.6 8
1/3 3/4 3.5 8
1/2 1 5.0 10
3/4 1 1/2 7.6 15
1 2 10 20
Minarik Corporation offers two fuse kits: part number 050–0069 (3–8A
Fuse Kit) and 050–0073 (5–20A Fuse Kit). Both fuse kits include a 1/2A
pico fuse (part number 050–0074) which protects the transformer and
logic.
m
m
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6Installation
Cage-clamp terminals
RG Series drive connections are made to cage-clamp terminals. To insert a
wire into a terminal, see Figure 4.
1. Press down on the lever arm using a
small screwdriver.
2. Insert wire into the wire clamp.
3. Release the lever arm to clamp wire.
Figure 4. Cage-Clamp Terminal
Field fusing
To protect the motor field of shunt wound motors, all RG501A and
RG511A drives have 1.5A 3AG field fuses installed to fuseholder FU503
(see Figure 3). If this fuse needs to be replaced, use a fuse of the same
rating.
Figure 3. Line and Field Fuses
Line and Field Fuses
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7
Installation
Figure 5. Connections
Prewired
Connections
Assumptions: Minarik®drives supply motor voltage from the A1
and A2 terminals. It is assumed throughout this manual that, when A1
is positive with respect to A2, the driven motor will rotate clockwise
(CW) while looking at the output shaft protruding from the front of
the motor. If the opposite is desired, simply reverse the wiring of A1
and A2 with each other.
m Minarik®assumes that the user has selected proper line-
balancing and/or power factor correction circuitry.
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8Installation
Limit switch connections (optional)
All connections to the logic
board are prewired (see prewired
connections on page 29). If your
application requires the use of limit
switches, connect the limit switches
to the logic board as shown in
Figure 6. If only the forward limit
switch is used, remove the reverse limit switch and jumper terminal 21 to
22. If only the reverse limit switch is used, remove the forward limit
switch and jumper terminal 20 to 22.
Remote pushbuttons
(optional)
Add external jog, stop, reverse
and forward pushbuttons to control
the drive from a remote location.
Connect normally open pushbuttons
to top board terminals 15 through 19
(see Figure 7). Case pushbuttons
may still be used if external
pushbuttons are connected.
Figure 6. Optional limit switch
connections
Figure 7. Optional remote pushbutton
connections
Field output
The field output is for shunt wound motors only. Do not make any
connections to the field output when using a permanent magnet motor.
See Table 2 for field output connections.
Table 2. Field Output Connections
Line Voltage Approximate Field Field
(VAC) Voltage (VDC) Connections
115 50 F1 and L1
115 100 F1 and F2
230 100 F1 and L1
230 200 F1 and F2
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9
Installation
Feedback Switch
Set to ARM for armature feedback,
or TACH for tachogenerator feedback.
Armature Voltage Switch
Set to 90 for 90 VDC motor, or
180 for 180 VDC motor.
Line Voltage Switches
Set to 115 for 115 VAC line voltage, or
230 for 230 VAC line voltage.
Slide switches
Set all slide switches to their proper setting before applying power (see
Figure 8 ).
Figure 8. Slide Switches
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10 Installation
Mode select switches
Mode select switches, located on the logic board (see Figure 9), are preset
with switch 1 OFF and switch 2 ON. This allows you to operate the drive
without the use of limit switches. Change mode select switch settings
when power is off. Make sure that terminals 20, 21, and 22 are jumpered if
limit switches are not used. If limit switches are used, set the mode select
switches to one of the four operating modes:
Figure 9. Mode Select Switches
Mode Select Switches
Mode 1 (1 and 2 OFF) – Half cycle between forward and
reverse limit switches.
Mode 2 (1 ON and 2 OFF) – Single cycle between forward
and reverse limit switches.
Mode 3 (1 OFF and 2 ON) – Continuous cycle between
forward and reverse limit switches.
Mode 4 (1 and 2 ON) – Single cycle with one limit switch.
See page 14 for more information on limit switch operating modes.
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11
Operation
Before applying power
•Verify that no conductive material is present on the printed circuit
board.
•Set all switches to their proper settings.
•Verify that the AC supply is properly balanced.
Startup
1. Set the power switch to 0(off); set forward and reverse speed adjust
potentiometers to 0; set FWD JOG and REV JOG trimpots to 50%
(12 o’clock).
2. Apply AC line voltage.
3. Set the power switch to I(on). The LED above STOP is lit.
3. To rotate the motor in the forward direction:
a. Press FWD . The LED above it lights.
b. Set the forward speed adjust potentiometer until the motor rotates
at the desired forward speed.
To rotate the motor in the reverse direction:
a. Press REV . The LED above it lights.
b. Set the reverse speed adjust potentiometer until the motor rotates at
the desired reverse speed.
5. To switch the direction of motor rotation, press the pushbutton of the
opposite direction.
6. Press STOP to stop the motor.
m
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12 Operation
Jogging the motor
The RG501A and RG511A has a jog option, allowing you to jog the
motor in the forward or reverse direction as long as the forward or reverse
pushbutton is pressed. The drive can be switched to the jog mode while the
motor is stopped, or is running in either the forward or reverse direction.
To jog the motor:
1. Press JOG to enter the jog mode.
2. To jog the motor in the forward direction:
a. Press and hold the FWD pushbutton. The motor jogs in
the forward direction. The motor speed is set by the FWD JOG
trimpot.
b. Release FWD to stop the motor.
To jog the motor in the reverse direction:
a. Press and hold the REV pushbutton. The motor jogs in
the reverse direction. The motor speed is set by the REV JOG
trimpot.
b. Release REV to stop the motor.
3. To exit the jog mode, press STOP .
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